EP2634657B1 - Numerisches steuerverfahren - Google Patents

Numerisches steuerverfahren Download PDF

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Publication number
EP2634657B1
EP2634657B1 EP11836368.8A EP11836368A EP2634657B1 EP 2634657 B1 EP2634657 B1 EP 2634657B1 EP 11836368 A EP11836368 A EP 11836368A EP 2634657 B1 EP2634657 B1 EP 2634657B1
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EP
European Patent Office
Prior art keywords
loop
velocity
transfer function
gain
control
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EP11836368.8A
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English (en)
French (fr)
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EP2634657A1 (de
EP2634657A4 (de
Inventor
Akira Kawana
Norio Mori
Mitsunari Oda
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Makino Milling Machine Co Ltd
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Makino Milling Machine Co Ltd
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
    • G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
    • G05B13/0205—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric not using a model or a simulator of the controlled system
    • G05B13/024—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric not using a model or a simulator of the controlled system in which a parameter or coefficient is automatically adjusted to optimise the performance
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/416—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control of velocity, acceleration or deceleration
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B5/00—Anti-hunting arrangements
    • G05B5/01—Anti-hunting arrangements electric
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/36—Nc in input of data, input key till input tape
    • G05B2219/36176—Edit servo control parameters
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/42—Servomotor, servo controller kind till VSS
    • G05B2219/42114—Loop mode, dual mode incremental coarse, analog fine

Definitions

  • the present invention relates to a numerical control method which uses a servo control unit to drive a feed axis of a machine tool.
  • the present invention relates to a numerical control method of a machine tool which is provided with a plurality of feed axes.
  • a machine tool includes one or more linear axes and/or rotary feed axes (below, these linear axes and rotary feed axes sometimes being simply referred to as the "feed axes").
  • the motors for driving these feed axes are controlled by a numerical control device.
  • different tools are attached depending on the content of the machining of a workpiece. Further, the jigs used for attaching workpieces to the machine tool differ according to the workpieces.
  • the feed axes have to be set with control parameters such as acceleration/deceleration time constants, reversal correction values, various types of gains and resonance filter constants.
  • PLT 1 discloses to adjust a feedback compensator (integral gain) as a control parameter by the time response of a motor and an ideal response error.
  • PLT 2 discloses to calculate a machine damage coefficient and to compare this with a threshold value so as to judge for abnormalities.
  • Document US 2005/033460 A1 may be construed to disclose a machine tool that moves a driven member by use of a servomotor.
  • a position control device controls the position of the driven member in accordance with full closed loop control.
  • the position control device computes an integrated feedback value g in correspondence with a function F (V M , P M , V m , P m ) in which four state amounts, motor speed V M , motor position P M , driven member speed V m , and driven member position P m are independent variables.
  • the thrust instruction ⁇ * which is inputted to the servomotor, is compensated with the integrated feedback value g.
  • the servomotor is thus optimally driven and controlled in accordance with full closed loop control.
  • Document JP H10-091 210 A may be construed to disclose a servo-control system adjusting working oil supplied from a hydraulic pressure source to a hydraulic cylinder by a servo valve and controlling the operation on a steering surface of an aircraft operated by this hydraulic cylinder by a controller equipped with a compensator which outputs a manipulated variable so that the controlled variable of the steering surface matches a target value.
  • the compensator is designed by robust control technology so that the compensator is robust and stable against a modelling error of the servo valve in addition to variation in the natural vibration frequency of the system consisting of the steering surface and hydraulic cylinder.
  • Document US 7,030,585 B2 may be construed to disclose a controller capable of preventing response delay and generation of vibrations attributable thereto during position control of a movable part of a machine having low rigidity.
  • a motor for driving a machine having low rigidity is subjected to position and velocity loop control.
  • Compensation amount Q 1 proportional to command velocity obtained by differentiating a position command and compensation amount Q 2 proportional to second-order differentiated command acceleration are obtained.
  • Compensation amounts Q 1 and Q 2 are added together, thus obtaining a velocity offset amount Vof corresponding to an estimated torsion amount.
  • a differentiated value of the velocity offset amount is multiplied by coefficient ⁇ to obtain a torque offset amount Tof.
  • the velocity offset amount Vof is added to a velocity command Vcs obtained by position loop control.
  • the torque offset amount Tof is added to a torque command Tc outputted in velocity loop control, and the result is used as a drive command to the motor.
  • a torsion amount between motor and the machine is controlled.
  • the machine position and velocity are controlled with accuracy by regular position and velocity loop control.
  • Document US 2009/112376 A1 may be construed to disclose a structure in which a thrust feed forward structure for operating a structure to be driven without vibration and a control structure which simultaneously compensates for positional deviation caused by the thrust feed forward structure and positional deviation caused by a base displacement are included in a position controlling device.
  • a structure is provided in which an acceleration and deceleration process for realizing response of the position of the structure to be driven and base displacement without vibration and a control structure which determines a feed forward amount with respect to a position instruction value after the acceleration and deceleration process are provided to the position controlling device.
  • PLT 1 does not disclose setting control parameters other than the feedback compensator. Furthermore, it does not disclose to automatically set the acceleration/deceleration parameters (acceleration, rate of change of acceleration, and required time at time of acceleration and deceleration) suitable for a current state of the feed axes.
  • the present invention was made in consideration of such a situation and has as its object to provide a numerical control method which can simply find a plurality of optimal control parameters and acceleration/deceleration parameters corresponding to the states of the feed axes and which can judge for abnormalities with a high reliability.
  • closed loop transfer functions and/or modeling errors which are obtained by creating a model of the operation of the servo control unit are used, so it is possible to quickly and automatically find a plurality of types of optimal control parameters.
  • acceleration/deceleration parameters acceleration, rate of change of acceleration, and required time at time of acceleration or deceleration
  • suitable acceleration/deceleration parameters acceleration, rate of change of acceleration, and required time at time of acceleration or deceleration
  • the plurality of types of optimal control parameters can be used to judge for abnormalities, so abnormalities can be judged in a multifaceted manner and the reliability of that judgment can be raised. Further, such judgment for abnormalities can be performed automatically, so it is possible to lighten the load on the operator.
  • the threshold value is made different depending on the type of the workpiece to be machined, the mass of the tool, etc.
  • FIG. 1 is a schematic view of a numerical control machine tool of the present invention.
  • the numerical control machine tool 10 is a so-called horizontal machining center and is provided with a bed 12 which is set on the floor surface of a factory etc.
  • Z-axis guide rails 28 are laid in the horizontal Z-axis direction (in FIG. 1 , left-right direction).
  • a table 14 for fastening a workpiece W through a workpiece-use jig G is slidably attached.
  • FIG. 1 is a schematic view of a numerical control machine tool of the present invention.
  • the numerical control machine tool 10 is a so-called horizontal machining center and is provided with a bed 12 which is set on the floor surface of a factory etc.
  • Z-axis guide rails 28 are laid in the horizontal Z-axis direction (in FIG. 1 , left-right direction).
  • a table 14 for fastening a workpiece W through a workpiece-use jig G is slidably attached.
  • FIG. 1 shows an example of a table 14 on which is fastened an NC rotary table which enables rotational feed in a B-axis direction and carries a workpiece W, but it is also possible to place the workpiece W directly on the table 14 without interposition of a NC rotary table.
  • X-axis guide rails 36 are laid perpendicularly intersecting the Z-axis in a horizontal X-axis direction (direction vertical to paper surface in FIG. 1 ).
  • a column 16 is slidably attached.
  • Y-axis guide rails 34 are laid in a Y-axis direction (in FIG. 1 , top-bottom direction) which perpendicularly intersects the X-axis and Z-axis.
  • a spindle head 18 which supports a spindle 20 to be able to rotate is slidably attached.
  • a Z-axis feed screw 24 is laid in the Z-axis direction.
  • a nut 26 which screws with the Z-axis feed screw 24 is fastened.
  • a Z-axis feed servo motor Mz is coupled. By driving the Z-axis feed servo motor Mz and making the Z-axis feed screw 24 rotate, the table 14 moves along the Z-axis guide rails 28.
  • an X-axis feed screw (not shown) is laid in the X-axis direction.
  • a nut which screws with the X-axis feed screw is fastened.
  • an X-axis feed servo motor Mx is coupled. By driving the X-axis feed servo motor Mx and making the X-axis feed screw rotate, the column 16 moves along the X-axis guide rails 36. Furthermore, inside of the column 16, a Y-axis feed screw 32 is laid in the Y-axis direction. At the back surface of the spindle head 18, a nut 30 which screws with the Y-axis feed screw 32 is fastened. At the top end of the Y-axis feed screw 32, a Y-axis feed servo motor My is coupled. By driving the Y-axis feed servo motor My and making the Y-axis feed screw 32 rotate, the spindle head 18 moves along the Y-axis guide rails 34.
  • a tool 22 for example, an end mill, is attached.
  • the tool 22 rotate while making the column 16, spindle head 18, and table 14 move in the X-axis, Y-axis, and Z-axis directions, respectively, the workpiece W which is fastened on the table 14 is cut to a desired shape.
  • the numerical control machine tool 10 can be said to be a four-axis numerical control machine tool which further has a B-axis.
  • the numerical control machine tool 10 is provided with a numerical control unit 40 which controls the X-axis, Y-axis, and Z-axis feed servo motors Mx, My, and Mz which make the column 16, spindle head 18, and table 14 move in the X-axis, Y-axis, and Z-axis directions.
  • a numerical control unit 40 which controls the X-axis, Y-axis, and Z-axis feed servo motors Mx, My, and Mz which make the column 16, spindle head 18, and table 14 move in the X-axis, Y-axis, and Z-axis directions.
  • a B-axis feed servo motor not shown.
  • the numerical control unit 40 includes a program reading/interpreting unit 44 which reads an NC program 42 and interprets it, an interpreted program storage unit 46 which temporarily stores the interpreted program, a program execution command unit 48 which suitably takes out a program from the interpreted program storage unit 46 and issues execution program data, a distribution control unit 50 which uses execution program data from the program execution command unit 48 as the basis to issue position command values, velocity command values, and torque command values to the X-axis, Y-axis, and Z-axis, and a servo control unit 52 which uses the position command values, velocity command values, and torque command values from the distribution control unit 50 and later explained feedback signals as the basis to issue torque command values or current command values to the feed axis motor drive unit 54.
  • the distribution control unit 50 issues a position command value, angular velocity command value, angular acceleration command value, etc. to the B-axis.
  • the feed axis motor drive unit 54 uses torque command values or current command values from the servo control unit 52 as the basis to output currents so as to drive the X-axis, Y-axis, and Z-axis feed axis motors Mx, My, and Mz. Furthermore, in the present embodiment, a processing control unit 56 is provided which corrects the torque command values or current command values from the servo control unit 52 to the feed axis motor drive unit 54.
  • the processing control unit 56 plays the role of performing various types of processing such as the later explained creation of a model and calculation of a control parameter.
  • FIG. 2 is a block diagram of the configuration of the servo control unit which controls the numerical control machine tool of the present invention.
  • component elements which correspond to FIG. 1 are indicated by the same reference notations.
  • the servo control unit 52 includes an acceleration/ deceleration processing unit 102 which processes the position command values from the distribution control unit 50 for acceleration/deceleration, a subtractor 58 which subtracts a position feedback signal of a digital linear scale or other position detector Sp which is attached to the table 14 from the position command values, and a position control unit 60 which uses the output from the subtractor 58 as the basis to control the position. Furthermore, the servo control unit 52 includes a reversal correction value calculation unit 96 which uses the positional command values from the distribution control unit 50 etc. as the basis to calculate correction values relating to backlash of the feed axes by a known technique.
  • the servo control unit 52 includes an adder 61 which adds the calculated reversal correction values to the velocity commands which are output from the position control unit 60, a subtractor 62 which subtracts the velocity feedback signals from the pulse coders PC which are provided at the feed axis motors M from the velocity commands, and a velocity control unit 64 which uses the output of the subtractor 62 as the basis to control the velocity.
  • the position command values, velocity command values, and torque command values from the distribution control unit 50 are sent at each instant to the velocity feed forward control unit 90 and the torque feed forward control unit 92.
  • the velocity feed forward control unit 90 and the torque feed forward control unit 92 use the position command values from the distribution control unit 50 as the basis to generate a velocity feed forward value and a torque feed forward value.
  • the velocity feed forward value and the output from the position control unit 60 are added at the adder 98 and supplied to the feed axis motor drive unit 54.
  • the torque feed forward value and the output from the velocity control unit 64 are added at the adder 94 and supplied to the feed axis motor drive unit 54.
  • FIG. 3 is a block diagram which shows the position control unit which is shown in FIG. 2 and its vicinity. As shown in FIG. 3 , the output from the subtractor 58 is multiplied with the position proportional gain (feedback gain of position loop) Kpp. Further, in FIG. 3 , a model of the feed forward gain of the velocity feed forward control unit 90 is created by the transfer function G VF .
  • a model of the region between the position commands after acceleration/deceleration processing and the actual position which is detected by the position detector Sp is created as a closed loop transfer function G BP of the position loop. Furthermore, as shown in FIG. 3 , inside the closed loop transfer function G BP , a model of the control coverage P p of the position loop is created, while inside the control coverage P p of the position loop, a control coverage model P p0 of the position loop is shown. Note that, in the figure, “s” is a Laplacian operator. Further, in FIG. 3 , " ⁇ P P " changes depending on the state of the machine tool, while the acceleration/deceleration processing unit 102, transfer function G VF , and position proportional gain K pp change by optimization.
  • FIG. 4 is a flow chart for calculating the control parameters relating to the position control unit. Note that, the following processing is assumed to be performed by the processing control unit 56. In the present invention, the processing which is shown in FIG. 4 is used to calculate control parameters of the position control unit 60 comprised of the transfer function G VF (feed forward gain) and position proportional gain K pp (feedback gain).
  • G VF feed forward gain
  • K pp position proportional gain
  • step S1 the closed loop transfer function G BP of the position loop is measured. This is found from the ratio of the position commands after the acceleration/deceleration processing which is shown in FIG. 3 and the actual position which is detected by the position detector Sp.
  • the modeling error ⁇ P p means the error with respect to an actual value which occurs due to creation of a model.
  • step S4 the following formula (3) is used to calculate the feed forward gain G VF (see FIG. 3 ) based on the modeling error ⁇ P p .
  • G VF s 1 + ⁇ P p
  • the group of data of the modeling error is used for approximation by the n-th order transfer function ⁇ cf (s).
  • the differential iteration method is used to find the coefficients of the transfer function. Note that, the calculation time is determined in accordance with the value of the order "n". When the order "n" is relatively small, the calculation time can be shortened, but the precision at the high frequency side is poor.
  • FIG. 5A is a first view which shows the technique of curve fitting of modeling error for approximation.
  • the ordinate shows the gain (db), while the abscissa shows the frequency "f" (Hz).
  • the transfer function ⁇ cf (s) for approximation generally matches the actual modeling error ⁇ at the low frequency side, but is greatly offset from the modeling error ⁇ at the high frequency side. [Equation 5] ⁇ ⁇ T ⁇ 1
  • the transfer function ⁇ cf (s) generally matches the actual modeling error ⁇ in all frequency regions. However, if the order "n" is large, the calculation takes time, so this is determined by considering the processing capability of the processing control unit 56. The thus obtained transfer function ⁇ cf (s) is used as the modeling error ⁇ P p to find the feed forward gain G VF from formula (3).
  • the small gain theorem is used to find the position proportional gain K pp by the formula (5) based on the closed loop transfer function G BP and modeling error ⁇ P p of the position loop. From the relationship derived by the small gain theorem, the stability is evaluated by whether the reciprocal of the closed loop transfer function (in formula (5), made "T") is larger than the modeling error ⁇ seen in terms of the frequency response in all frequency regions.
  • FIG. 6 is a view for explaining using the small gain theorem to find the feedback gain from the modeling error.
  • the ordinate shows the gain (db), while the abscissa shows the frequency "f" (Hz).
  • the reciprocal of the closed loop transfer function T is preferably close to the modeling error ⁇ , while the reciprocal of the closed loop transfer function T is desirably made to shift toward the modeling error ⁇ in the arrow direction.
  • the reciprocal of the closed loop transfer function T is set near the modeling error ⁇ without crossing or touching the modeling error ⁇ (please see solid line of FIG. 6 ).
  • the closed loop transfer function G BP of the position loop is determined and the formula (1) etc. are used to calculate the position proportional gain K pp .
  • FIG. 7 is a block diagram which shows the velocity control unit which is shown in FIG. 2 and its vicinity.
  • the reversal correction values which were prepared by the reversal correction value calculation unit 96 are added at the adder 61 to the velocity commands and, furthermore, the velocities which were detected at the pulse coders PC are subtracted at the subtractor 62.
  • the output from the subtractor 62 is branched. On the one hand, it is multiplied with the proportional gain K vp (first feedback gain of velocity loop), while on the other hand, it is multiplied with the integral gain K vi (second feedback gain of velocity loop) and the reciprocal of the Laplacian operator "s".
  • the products are added at the adder 94.
  • a model of the torque feed forward control unit 92 is created by the transfer function G AF . Its output is also added at the adder 94 and the result is input to the vibration suppression filter 100.
  • a model of the region between the velocity commands from the distribution control unit 50 and the actual velocities which are detected by the pulse coders PC is created as the closed loop transfer function G BV of the velocity loop. Furthermore, as shown in FIG. 7 , at the inside of the closed loop transfer function G BV , a model of the control coverage P V of the velocity loop is created. Furthermore, inside the control coverage P V of the velocity loop, the control coverage model P V0 of the velocity loop is shown. Note that, in the figure, “s” is a Laplacian operator, "J” is inertia, and "K t " is a torque constant. The torque constant K t , "1/Js", and " ⁇ P V " in FIG. 7 are assumed to change depending on the state of the machine tool, while the transfer function G AF , proportional gain K vp , integral gain K vi , and resonance filter 100 are assumed to change by optimization.
  • FIG. 8 is a flow chart for calculation of a control parameter relating to the velocity control unit. Note that, the following processing is assumed to be performed by the processing control unit 56. In the present invention, the processing which is shown in FIG. 8 is used to calculate the transfer function G AF (feed forward gain) and proportional gain K vp and integral gain K vi (feedback gains) as control parameters of the velocity control unit 64.
  • G AF feed forward gain
  • K vp proportional gain
  • K vi feedback gains
  • step S11 the closed loop transfer function G BV of the velocity loop is measured. This is found from the ratio of the velocity commands which are shown in FIG. 7 and the actual velocities which are detected by the pulse coders PC.
  • FIG. 9A and FIG. 9B are views which show the technique for finding the modeling error ⁇ P V of the velocity loop.
  • the ordinate shows the gain (db), while the abscissa shows the frequency "f" (Hz).
  • Hz the frequency "f"
  • step S14 the following formula (8) is used to calculate the feed forward gain G AF (see FIG. 7 ) based on the modeling error ⁇ P v .
  • G AF J ⁇ ⁇ S K ⁇ 1 1 + ⁇ P v
  • step S15 the velocity proportional gain Kvp and integral gain Kvi are found based on the closed loop transfer function GBV and modeling error ⁇ Pv of the velocity loop by using the small gain theorem.
  • the method of finding these gains is generally the same as step S5 of FIG. 4 , so details will be omitted.
  • the closed loop transfer function GBV of the velocity loop is determined in this way.
  • the formula (6) etc. are used to find the velocity proportional gain Kvp and integral gain Kvi.
  • the modeling errors ⁇ Pp and ⁇ P V of the position loop and the velocity loop which are obtained by creating a model of the operation of the servo control unit 52 are used to calculate the feed forward gains GVF and GAF. Furthermore, in the present invention, the closed loop transfer functions GBP and GBV and the modeling errors ⁇ Pp and ⁇ Pv of the position loop and the velocity loop are used to find the feedback gains Kpp, Kvi, and Kvp.
  • these gains GVF, GAF, Kpp, Kvi, and Kvp are all control parameters of the numerical control machine tool 10.
  • the closed loop transfer function and/or modeling error which are obtained by creation of a model are used, so the optimal control parameters suitable for the state of the feed axis are obtained. For this reason, in the present invention, at the time of machining, it is possible to quickly and automatically find a plurality of types of control parameters by calculation. Therefore, in the present invention, it becomes possible to maintain the grade of the machined surface and shape precision of the workpiece W at high levels.
  • FIGS. 10A and 10B are views which show the relationship between the gain and the frequency.
  • the modeling error ⁇ P v is extracted from the content of FIG. 9B .
  • error relatively concentrates in the region Z of the high frequency side.
  • This region Z can be automatically easily specified from a comparison of the average value of the gains and the values of the individual gains. Therefore, if selecting the resonance filter constant of the vibration suppression filter 100 so as to suppress the value of this region Z, as shown in FIG. 10B , it is possible to prepare a control coverage model P v0 with little error.
  • the resonance filter constant of this vibration suppression filter 100 is also one of the control parameters of the numerical control machine tool 10. Therefore, it will be understood that by such processing, in the present invention, a further larger number of control parameters can be automatically set.
  • the feed axes are set with acceleration/deceleration parameters (acceleration, rate of change of acceleration, and required time at time of acceleration/deceleration and allowable acceleration, corner deceleration, and interpolated acceleration/deceleration), but such acceleration/deceleration parameters have to be changed in accordance with the mass of the workpiece W, that is, the load of the feed axes.
  • the "allowable acceleration” parameter is the acceleration which is defined by the radius of curvature of the tool path and the command velocity
  • the "corner deceleration” parameter is the deceleration velocity for suppressing position error which occurs due to the effects of the discontinuity of the acceleration at corner parts
  • the "interpolated acceleration/deceleration” parameter is the time constant of the filter which is used for preventing the acceleration and the rate of change of acceleration from becoming infinitely large.
  • FIG. 11A is a view which shows the relationship between a feed velocity of a feed axis and time
  • FIG. 11B is a view which shows the relationship between acceleration and time.
  • a plurality of sets of the acceleration ⁇ and the acceleration change rate ⁇ ' are stored in a storage unit (not shown).
  • the time TA shows the time for the feed velocity to change from zero to a certain value
  • the time TB shows the time for the acceleration ⁇ to change from zero to a certain value.
  • the sets comprised of the acceleration ⁇ and the acceleration change rate ⁇ ' are successively input one at a time at the acceleration/deceleration processing unit 102 to process the position commands for acceleration or deceleration.
  • the values obtained from the closed loop transfer function G BP of the position loop are compared with the actual positions and it is judged if the differences are within a predetermined range.
  • Such processing is performed successively until "n" sets so as to extract the sets with the above differences within a predetermined range. Then, from such sets, the sets with a rate of change of acceleration ⁇ ' of a predetermined value or less are extracted. This is because if the rate of change of the acceleration is large, shaking, vibration, etc. occur at the numerical control machine tool 10, so such cases are excluded. Finally, from the extracted sets, the set with the shortest time TA is selected and is set as the acceleration/deceleration parameters.
  • FIG. 14 is a view which shows one machining path of a tool of a machine tool.
  • the tool 22 is shown moving from one straight path AB through the arc path BC to the other straight path CD.
  • the radius of the arc path BC is made "R".
  • Such a machining path is found by analyzing the NC program 42. Further, the broken line shows enlarged the actual path when the machine operates for this machining path.
  • FIG. 15A and FIG. 15B are views which show the relationships of the X-direction velocity, X-direction acceleration, and X-direction error at FIG. 14 with time.
  • the waveforms show the results found by simulation.
  • FIG. 15A shows the state where the velocity V X is relatively large (F 1 ), so the acceleration ⁇ X is also large (-F 1 2 /R) and, as a result, the error E X at the point C is also large (e 1 ).
  • FIG. 15B shows the state where the velocity V X is relatively small (F 2 ), so the acceleration ⁇ X is also small (-F 2 2 /R) and, as a result, the error E X at the point C is also small (e 2 ).
  • a suitable velocity V X is found so that the disturbance of the actual path becomes within an allowable value, and the threshold parameter of the acceleration (F 2 /R) which is included in the acceleration/deceleration processing unit 102 of FIG. 2 and which is calculated from the radius R and the command velocity F is automatically determined.
  • a predetermined initial value F 0 and a radius R are set for the command velocity F and the radius R which are shown in FIG. 14 .
  • a position command relating to the X-axis of step S32 is prepared.
  • that position command is input for the position command of the position control unit 60 of FIG.
  • the acceleration/deceleration parameters which are set at the acceleration/deceleration processing unit 102 of FIG. 2 become suitable for the state of the feed axes. Further, the position control unit 60 is used for calculation by simulation without actually operating the machine tool, so it is possible to find the optimal acceleration/deceleration parameters in a short time.
  • FIG. 12 is a flow chart which shows the processing for judging for abnormalities based on a control parameter. As shown in FIG. 12 , at step S21, it is confirmed which control parameter the control parameter which was calculated by the present invention is.
  • the set of the threshold values which are preset for that control parameter is read from a storage unit (not shown).
  • the set of threshold values is determined by experiments etc. and includes a first threshold value and a second threshold value which is larger than the first threshold value. These threshold values are made different in accordance with the type of the workpiece W to be machined, the mass of the tool, etc.
  • step S23 it is judged if the control parameter is larger than the first threshold value. If larger, the routine proceeds to step S24 where the operator is issued a visual or auditory warning. Further, at step S25, it is judged if the control parameter is larger than the second threshold value. If larger, the routine proceeds to step S26 where the numerical control machine tool 10 itself is made to stop.
  • control parameters are obtained. Further, these control parameters are used as indicators of judgment for abnormalities. Therefore, it is possible to judge the presence of abnormalities uniquely in accordance with the different control parameters.
  • control parameter is the resonance filter constant of the vibration suppression filter 100
  • control parameters it is possible to perform other types of judgments for abnormalities.
  • the present invention it is possible to use the plurality of types of optimized control parameters for judgment for abnormalities in a multifaceted manner and as a result possible to raise the reliability of the judgment for abnormalities. Furthermore, in the present invention, since such judgment for abnormalities can be performed automatically, the load on the operator can be lightened. It is also possible to make the numerical control method of the present invention be automatically run at the time of powering up a machine tool and check the status of the machine tool from the daily changes in optimized control parameters.
  • FIG. 13A is a view which simply shows a position loop.
  • the position commands of the machine tool which are shown in FIG. 13A are maintained in amplitude while changed in frequency and input in, for example, the range of 10 Hz to 1000 Hz.
  • the output which passes through the compensator 81 and plant 82 is detected by a scale or servo motor encoder. Then, the input and the output can be transformed by Fourier transforms and the ratio of the same found so as to find the transfer function G BP .
  • FIG. 13B is a view which simply shows a velocity loop.
  • the servo motor is operated as shown in FIG. 13B , and the torque is maintained in amplitude while changed in frequency and, for example, input in the range of 10 Hz to 1000 Hz.
  • the output which passes through the compensator 81 and the plant 82 is detected by the torque detector etc.
  • the input and the output can be transformed by Fourier transforms and the ratio of the same found so as to find the transfer function G BV .
  • the velocity may also be directly input.
  • the time required for inputting position commands etc. while changing the frequency between for example 10 Hz to 1000 Hz in range is several seconds. Further, in such work, it is not necessary to actually operate the machine tool. For this reason, it will be understood that the transfer functions G BP and G BV can be calculated in an extremely short time. Furthermore, the plant 82 usually includes models of machine tools and error, for example, conversion delay at the time of analog-digital conversion. In the present invention, various types of judgments are made through the transfer functions G BP and G BV , so it will be understood that results closer to the actual operation of the machine tool are obtained.

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Claims (8)

  1. Numerisches Steuerungsverfahren, das eine Servosteuereinheit (52) zum Antreiben einer Vorschubachse einer Werkzeugmaschine (10) verwendet,
    wobei das numerische Steuerungsverfahren folgende Schritte umfasst Messen (S1) einer Regelungstransferfunktion (GBP) einer Positionsschleife an der Servosteuereinheit der Werkzeugmaschine unter Verwendung einer Frequenzantwort der Vorschubachse,
    Auffinden (S2) einer Kontrollabdeckung, PP, der Positionsschleife unter Verwendung der gemessenen Regelungstransferfunktion, GBP, unter Verwendung der folgenden Gleichung: P P = G BP K PP 1 − G BP ,
    Figure imgb0013
     wobei KPP die positionsproportionale Verstärkung der Positionsschleife ist,
    Auffinden (S3) eines Modellierungsfehlers (ΔPP) der Positionsschleife aus der Kontrollabdeckung (PP), und
    Berechnen (S5) der positionsproportionalen Verstärkung KPP der Positionsschleife als einen Steuerparameter aus der Regelungstransferfunktion GBP der Positionsschleife und dem Modellierungsfehler (ΔPP) der Positionsschleife, wobei i) die Regelungstransferfunktion (GBP) so eingestellt ist, dass sie den Modellierungsfehler (ΔPP) nicht überschreitet, und ii) das Theorem der kleinen Verstärkung verwendet wird, um KPP unter Verwendung der folgenden Gleichung zu finden: ΔP P < T − 1 ,
    Figure imgb0014
     wobei T die Regelungstransferfunktion GBP ist und in Richtung des Modellierungsfehlers (ΔPP) in eine Richtung verschoben wird, in der die Frequenz zunimmt.
  2. Numerisches Steuerungsverfahren, das eine Servosteuereinheit zum Antreiben einer Vorschubachse einer Werkzeugmaschine verwendet,
    wobei das numerische Steuerungsverfahren folgende Schritte umfasst
    Messen (S11) einer Regelungstransferfunktion (GBV) einer Geschwindigkeitsschleife an der Servosteuereinheit der Werkzeugmaschine unter Verwendung einer Frequenzantwort der Vorschubachse,
    Auffinden (S12) einer Kontrollabdeckung, PV, der Geschwindigkeitsschleife unter Verwendung der gemessenen Regelungstransferfunktion, GBV, gemäß der folgenden Formel: P V = G BV C V 1 − G BV ,
    Figure imgb0015
     wobei Cv die Summe aus einer geschwindigkeitsproportionalen Verstärkung (Kvp) der Geschwindigkeitsschleife und des Produkts einer integralen Verstärkung (Kvi) der Geschwindigkeitsschleife und des Kehrwerts des Laplace-Operators "s" ist,
    Auffinden (S13) eines Modellierungsfehlers (ΔPV) der Geschwindigkeitsschleife aus der Kontrollabdeckung (Pv), und
    Berechnen (S15) der geschwindigkeitsproportionalen Verstärkung (Kvp) der Geschwindigkeitsschleife und der Integralverstärkung (Kvi) als Steuerparameter aus der Regelungstransferfunktion GBV, der Geschwindigkeitsschleife und dem Modellierungsfehler (ΔPV) der Geschwindigkeitsschleife, wobei i) der Kehrwert der Transferfunktion GBV daran gehindert wird, den Modellierungsfehler (ΔPV) zu überschreiten, indem das Verhältnis der geschwindigkeitsproportionalen Verstärkung (Kvp) und der Integralverstärkung (Kvi) eingestellt wird, und ii) das Theorem der kleinen Verstärkung verwendet wird, um Cv unter Verwendung der folgenden Gleichung zu finden: ΔP P < T − 1 ,
    Figure imgb0016
     wobei T die Regelungstransferfunktion GBV ist und in Richtung des Modellierungsfehlers (ΔPV) in eine Richtung verschoben wird, in der die Frequenz zunimmt.
  3. Numerisches Steuerungsverfahren nach Anspruch 1, das den Modellierungsfehler (ΔPP) der Positionsschleife verwendet, um eine Vorwärtsverstärkung (GVF) der Positionsschleife als einen Steuerparameter aufzufinden (S4).
  4. Numerisches Steuerungsverfahren nach Anspruch 2, das den Modellierungsfehler der Geschwindigkeitsschleife verwendet, um eine Vorwärtsverstärkung (GAF) der Geschwindigkeitsschleife als einen Steuerparameter aufzufinden (S14).
  5. Numerisches Steuerungsverfahren nach Anspruch 2, das ferner umfasst:
    Bereitstellen eines Graphen, der die Beziehung zwischen einem Modell (Pv0) für die Kontrollabdeckung der Geschwindigkeitsschleife und der Frequenz aufzeigt;
    Einstellen der Kontrollabdeckung (Pv) der Geschwindigkeitsschleife derart, dass sie mit dem Modell (Pv0) für die Kontrollabdeckung der Geschwindigkeitsschleife auf einer niederfrequenten Seite in dem Graphen übereinstimmt;
    Einstellen des Bereichs der Differenz zwischen der Kontrollabdeckung (Pv) und dem Modell (Pv0) als den Modellierungsfehler (ΔPv);
    Vergleichen des Mittelwerts der Verstärkungen des Modellierungsfehlers (ΔPv) und der Werte der einzelnen Verstärkungen, um einen Bereich (Z) zu bestimmen, in dem sich der Fehler konzentriert; und
    Auffinden einer Resonanzfilterkonstante als einen Steuerparameter eines Schwingungsunterdrückungsfilters, um die Verstärkung des Bereichs Z zu unterdrücken.
  6. Numerisches Steuerungsverfahren nach Anspruch 1, das
    die Regelungstransferfunktion GBP der Positionsschleife in der Servosteuereinheit der Werkzeugmaschine auffindet,
    eine Vielzahl von Sätzen eingibt, die zumindest vorbestimmte Beschleunigungen (α) der Vorschubachse und Zeiten (TB) für die Änderung der Beschleunigung (α) von Null auf einen bestimmten Wert in der Regelungstransferfunktion GBP der Positionsschleife umfassen, und
    als Beschleunigungs-/Verzögerungsparameter einen Satz auswählt, der zumindest die Beschleunigung (α) und die Zeit (TB) aus der Vielzahl von Sätzen umfasst, so dass ein Fehler zwischen einem Positionsbefehl und einer Ist-Position der Vorschubachse zu einem Soll-Wert oder weniger wird.
  7. Numerisches Steuerungsverfahren nach Anspruch 1 oder 2, das
    den berechneten Steuerparameter und einen vorbestimmten Schwellenwert für jenen Steuerparameter vergleicht und
    eine Warnung ausgibt, wenn der Steuerparameter den Schwellenwert oder mehr beträgt.
  8. Servosteuereinheit (52) zum Antreiben einer Vorschubachse einer Werkzeugmaschine (10), wobei die Servosteuereinheit konfiguriert ist, um alle Schritte eines Verfahrens gemäß zumindest einem der vorhergehenden Verfahrensansprüche auszuführen.
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